CN105428295B - Adjusting substrate temperature to improve Critical Dimension (CD) uniformity - Google Patents

Adjusting substrate temperature to improve Critical Dimension (CD) uniformity Download PDF

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CN105428295B
CN105428295B CN201510733658.8A CN201510733658A CN105428295B CN 105428295 B CN105428295 B CN 105428295B CN 201510733658 A CN201510733658 A CN 201510733658A CN 105428295 B CN105428295 B CN 105428295B
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基思·威廉·加夫
哈米特·辛格
基思·科门丹特
瓦希德·瓦赫迪
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Lam Research Corp
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    • H01L21/76801—Applying interconnections to be used for carrying current between separate components within a device comprising conductors and dielectrics characterised by the formation and the after-treatment of the dielectrics, e.g. smoothing
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Abstract

A plasma etching system having a substrate support assembly with a plurality of independently controllable heater zones. The plasma etching system is configured to control the etch temperature at predetermined locations so that pre-etch and post-etch non-uniformities of critical device parameters can be compensated for.

Description

Adjusting substrate temperature to improve Critical Dimension (CD) uniformity
The present application is a divisional application of an invention patent application having an application number of 201080055995.1, application date of 2010, 12/13/d, filed by lamm research corporation entitled "adjusting substrate temperature to improve uniformity of Critical Dimension (CD)".
RELATED APPLICATIONS
The present application claims priority from U.S. provisional application No.61/286,653, filed 2009, 12, 15, 119, the entire contents of which are incorporated herein by reference.
Background
With the advent of various subsequent semiconductor technologies, the diameter of substrates such as wafers tends to increase and transistor size becomes smaller, resulting in a need for a higher degree of accuracy and repeatability in substrate processing. Semiconductor substrate materials, such as silicon substrates, are processed by techniques including the use of vacuum chambers. These techniques include both non-plasma applications such as electron beam deposition and plasma applications such as sputter deposition, Plasma Enhanced Chemical Vapor Deposition (PECVD), resist stripping, and plasma etching.
Plasma etching systems available today are among those semiconductor manufacturing tools that have an ever-increasing need for improved accuracy and repeatability. One metric for plasma etch systems is uniformity improvement, which includes uniformity of process results across the surface of a semiconductor substrate and uniformity of process results for a series of substrates processed with nominally the same input parameters. A continuous improvement in uniformity across the substrate may be desirable. In addition, there is a need for a plasma chamber with improved uniformity, consistency and self-diagnostics.
Disclosure of Invention
Disclosed herein is a method of using a plasma etching system that includes a substrate support assembly that supports a substrate during plasma etching, the substrate support assembly including a plurality of independently controllable heater zones arranged at device die locations (device die locations) on the substrate and a control unit that controls each of the heater zones. The method includes (a) measuring pre-etch or post-etch critical device parameters of a previously etched substrate at a substrate device die location on the substrate; (b) transmitting pre-etch and post-etch critical device parameters to a plasma etch system; (c) thereafter supporting the substrate on the substrate support assembly; (d) transmitting the process recipe parameters to the plasma etch system and/or loading the process recipe parameters in memory into the plasma etch system; (e) inferring a target etch temperature at a predetermined location on a substrate from target post-etch and pre-etch critical device parameter data input for the substrate based on process recipe parameters and/or post-etch critical device parameters for a previously etched substrate; (f) adjusting the temperature of each predetermined location based on the target etch temperature at the predetermined location by applying a controllable heater zone; and (g) plasma etching the substrate.
Detailed Description
In semiconductor processing apparatus, it is becoming increasingly desirable to control the radial or azimuthal substrate temperature to achieve a target Critical Dimension (CD) uniformity across the substrate. Even small changes in temperature can affect CD to an unacceptable degree, particularly when the CD is near sub-20nm (sub-20nm) during semiconductor fabrication.
The substrate support assembly may be configured to perform various functions during processing, such as supporting the substrate, adjusting the temperature of the substrate, providing rf power. The substrate support assembly may include an electrostatic chuck (ESC) for electrostatically clamping a substrate to the substrate support assembly during processing. The ESC may be an adjustable electrostatic chuck (T-ESC). T-ESC is described in commonly assigned U.S. patent nos. 6,847,014 and 6,921,724, which are incorporated by reference into this application. The substrate support assembly may include a ceramic substrate holder, a fluid-cooled heat sink (hereinafter referred to as a cold plate), and a plurality of coaxial heating zones to gradually effect radial temperature control. Typically, the cooling plate is maintained between 0 ℃ and 30 ℃. The heater is disposed on the cooling plate with a thermal insulation layer therebetween. The heater may maintain the support surface of the substrate support assembly at a temperature of about 0 ℃ to 80 ℃ above the temperature of the cooling plate. By varying the heating power in the plurality of heater zones, the substrate support temperature profile can be varied between being heated in the center region, cooled in the center region, and uniform. Still further, the average substrate support temperature is gradually varied over an operating range of about 0 ℃ to 80 ℃ above the chill plate temperature. As CD decreases with advances in semiconductor technology, small azimuthal temperature variations present increasingly greater challenges.
Controlling the temperature is not an easy matter for various reasons. First, many factors can affect heat transfer, such as the location of the heat source and heat sink, the movement, material, and shape of the media. Second, heat transfer is a dynamic process. Heat transfer will occur unless the associated system is in thermal equilibrium, and the temperature profile and heat transfer will vary over time. Third, non-equilibrium phenomena, such as plasma, of course, always exist in plasma processing processes, making theoretical expectations of the heat transfer performance of any practical plasma processing apparatus very difficult, if not impossible.
In plasma processing apparatuses, the substrate temperature profile is affected by many factors, such as the plasma density profile, the RF power profile, the details of the various heating and cooling elements in the chuck, and therefore the substrate temperature profile is generally not uniform and difficult to control with a small number of heating or cooling elements. The defects translate into non-uniformities in processing rates across the entire substrate and non-uniformities in critical dimensions of device tubes on the substrate.
The non-uniformity in the critical dimensions may be caused by upstream process flows, such as photolithography. Post-lithographic and pre-etch substrates typically have non-uniformity in device features due to the fact that lithographic parallel features (e.g., all device dies exposed on the substrate at the same time) and factors such as source non-uniformity, diffraction on the photomask, non-uniformity in temperature, non-uniformity in photoresist thickness, etc. are difficult to control. Such non-uniformity can lead to reduced device yield if unchecked and passed on to downstream process flows.
It would be advantageous and desirable to provide multiple independently controllable heater zones in a substrate support assembly to enable a plasma etching system to efficiently generate and maintain a given spatial and temporal temperature profile, and to compensate for other adverse factors that affect CD uniformity.
A substrate support assembly with independently controlled heater zones is disclosed in U.S. patent application No. 12/582,991 filed on 21/10/2009, which is incorporated herein by reference.
Described herein are methods of using a plasma etching system having a substrate support assembly with a plurality of independently controllable heater zones to compensate for non-uniformities in a substrate to be etched during an etching process by measuring pre-etch critical device parameters at a plurality of device die locations on the substrate or post-etch critical device parameters of a previously etched substrate and using the measured information to adjust the temperature at predetermined locations on the substrate.
For example, after the substrate is subjected to lithography, a pattern is formed on a resist layer of the substrate. There may be non-uniformity in the critical dimension of the pattern on the resist layer. The pre-etch critical dimension in the resist layer on each device die on the substrate may be measured with a suitable tool. The patterned resist layer is used as a mask in subsequent plasma etching of the underlying substrate. The temperature of the plasma etch process can affect the critical dimension of the pattern being etched on the substrate (post-etch critical dimension). If the pre-etch critical dimension determination at the device die location falls outside of a tolerable error from the target value, the etch temperature at the device die location may be adjusted by the heater zone to bring the post-etch critical dimension within the tolerable error from the target value. Thus, the measured pre-etch critical dimension may be used to adjust the etch temperature at each device die location to compensate for a specified amount of error in the pre-etch critical dimension at the device die location.
The plasma etching system can have independently controllable heater zones assembled in a heater plate and a control unit that controls each heater zone. By adjusting the power to each heater zone, the temperature profile during processing can be shaped radially and azimuthally under the control of the control unit. The heater zones are preferably arranged in a defined pattern, for example, a rectangular grid, a hexagonal grid, or other pattern. Each heater region of the heater plate is preferably of similar size (e.g., ± 10%) to an individual device die on the substrate. In a typical arrangement, to reduce the number of wire connections, power supply lines and power return lines are provided, each connected to a different group of heater zones, and each connected to a different group of heater zones, with each heater zone being in one of the groups connected to a particular power supply line and in one of the groups connected to a particular power return line. The two heater zones are not connected to the same pair of power supply and power return lines. Thus, the heater zones may be triggered by directing current through a pair of power supply and power return lines to connect to a particular heater zone. The power of the heater element is preferably less than 20W, more preferably 5W to 10W. The heater element may be a Peltier device and/or a resistive heater, such as a polyimide heater, a silicone rubber heater, a mica heater, a metal heater (e.g., W, Ni/Cr alloy, Mo or Ta), a ceramic heater (e.g., WC), a semiconductor heater, or a carbon heater. The heater element may be a screen printed, wire wound or etched foil heater. The thickness of the heater element may range from 2 microns to 1 mm, preferably 5-80 microns. To be provided in the heater zone and/or power supplyThe total area of the space between the supply line and the power return line, the heater region, may be up to 90% of the area of the upper surface of the substrate support assembly, for example 50-90% of that area. The power supply lines or power return lines (collectively power lines) may be provided in gaps ranging from 1 to 10mm between heater zones, or in separate planes separated from the heater zones by electrically insulating layers. The power supply line and the power return line are preferably made as wide as the space allows in order to deliver a large current and reduce joule heating. The power supply line may be in the same plane as the heater zones or may be in a different plane than the heater zones. The material of the power supply line and the power return line may be the same as or different from the material of the heater element. Preferably, the material of the power supply line and the power return line is a material having low resistance, such as Cu, Al, W,
Figure BDA0000836940210000051
Or Mo. The substrate support assembly is operable to control the substrate temperature and, thus, the plasma etch process at each device die location, thereby maximizing device yield on the substrate. The plasma etch system preferably has 9 heater zones.
In one embodiment, a plasma etch system may receive critical device parameters (e.g., pre-etch critical dimensions) measured at a plurality of device die locations (preferably at least one location on each device die location) on a substrate to be processed in the system from a source such as a human user, an on-board metrology tool, a network of hosts (a network that shares data among processing tools within a processing line), and the like. Preferably, the plasma etch system can receive a batch of pre-etch critical device parameters for a substrate to be processed from an off-board inspection tool via a host communication network. Such off-line inspection tools may be optical and/or electron beam inspection tools. The plasma etch system may have a software and/or hardware interface to receive pre-etch critical device parameters. The plasma etch system may have suitable software to process the pre-etch critical device parameters.
The plasma etch system may also receive and/or load, via a hardware and/or software interface, process recipe parameters defining a correlation of a target post-etch critical device parameter with measured pre-etch critical device parameters and etch temperature; and inferring a target etch temperature at a predetermined location on the substrate from the process recipe parameters, the target post-etch critical device parameters, and the measured pre-etch critical device parameters. Preferably, the plasma etch system can receive such process recipe parameters for each process recipe phase.
Preferably, the plasma etching system can further calculate target control parameters (parameters that can be directly controlled, such as power, voltage, current, etc.) for each heater zone based on the target etch temperature for each device die location to obtain target critical device parameters for each device die.
The target control parameter may be obtained by measuring the response of the surface temperature of the substrate support assembly to different control parameters applied thereto during the production of the substrate support assembly. Alternatively, the target control parameters may be determined using theoretical or empirical models, such as thermal transfer theory or finite element analysis.
Preferably, the steady state gain matrix can be used to calculate the target control parameter by the direct response of each device die location to the controllable parameter applicable to the bottom heater zone and by the indirect response of the device die to the controllable parameter applicable to the other heater zones (crosstalk). The steady state gain matrix may be calculated using the method described in matrix calculation, g, Golub et al (published by the university of johns hopkins, boston, 1996), the entire contents of which are incorporated herein by reference.
In one embodiment, assume that the plasma etch system has n independent heater zones. Their respective control parameters are Xi(i ﹦ 1,2, …, n). All control parameters XiThe following vectors can be written:
Figure BDA0000836940210000061
wherein XiPreferably the time-averaged power for the ith heater zone.
TiIs the target etch temperature at the device die location in the ith heater zone, another vector can be written:
Figure BDA0000836940210000062
vector T is a function of vector X. The relationship between the vectors X and T can be described by an n X n order matrix K, where T ﹦ K · X. Diagonal line element K in the production of a substrate support assembly or plasma etching systemiiCan be measured. Off-diagonal factor K in a substrate support assembly or plasma etch system production processij(i ≠ j) can be measured or derived from the finite element thermal model, the values of the diagonal elements, and the values of the physical distance between the ith and jth heater zones. The matrix K is stored within the plasma etching system. The plasma etch system also has software or firmware that can be used to execute an algorithm that derives X based on T. The algorithm is to multiply the inverse matrix by the matrix, i.e., X ﹦ K-1·T。
In another embodiment, assume that the plasma etch system has n independent heater zones. Their respective control parameters are Xi(i ﹦ 1,2, …, n). All control parameters XiThe following vectors can be written:
Figure BDA0000836940210000071
wherein XiPreferably the time-averaged power for the ith heater zone.
P﹦﹛PjThe predetermined locations on the substrate are a set of asserted etch temperatures, the temperatures on the substrate in response to each heater region being known based on existing models or standard dimensions. P can be written as another vector:
Figure BDA0000836940210000072
T﹦﹛Tjthe money is a set of the same predetermined location target etch temperatures on the substrate. T can be written as the following vector:
Figure BDA0000836940210000073
in this embodiment, the number m of locations on the substrate with respective target etch temperatures is not equal to the number of heater zones, e.g., m ≠ n. The location of the temperature response may be different from the location of the heater zone. Vector P is a function of vector X. The relationship between the vectors P and T can be described by an m X n order matrix K, where P ﹦ K · X. Element K during the production of a substrate support assembly or plasma etching systemijMay be measured or derived from a defined element thermal model. The matrix K is stored within the plasma etching system. By employing a matrix or optimization calculation program, such as least squares optimization, the plasma etch system also has software or firmware that can be used to execute an algorithm to derive X from T using a matrix and optimization algorithm (e.g., least squares optimization). The optimization algorithm simplifies the calculation of the heater power set point (setpoint) by minimizing the difference between the predetermined temperature of the device die location and the target temperature of the respective location on the substrate.
In the above embodiments, the location at which substrate features such as CD values are measured may vary depending on the number of heater zones. In addition, the location of the measured substrate features is not consistent with the location of the temperature response of each heater zone that is known based on, for example, a model during production or previous measurements. More specifically, the substrate feature measurement locations are different from the locations used to construct the matrix K. Therefore, the substrate characteristics need to be estimated at the same location as used to construct the matrix K. In a preferred embodiment, techniques such as linear or non-linear interpolation may be used to transition the substrate characterization data, such as CD values, from the substrate characteristic measurement location to a location where the individual heater responses have been patterned or measured during the calibration process, i.e., where the matrix K is constructed.
In an alternative embodiment, the control parameters may be dynamically determined by a control circuit (e.g., a PID controller) based on the output of the temperature sensor (e.g., photosensor, thermocouple, diode, etc.) for each heater zone.
While the method of using the plasma etching system has been described in detail with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made, and equivalents employed, without departing from the scope of the appended claims.

Claims (6)

1. A plasma etching system comprising a substrate support assembly for supporting a substrate during plasma etching, the substrate support assembly comprising
A plurality of independently controllable heater zones arranged below the substrate for providing radial and azimuthal temperature control across the substrate in the presence of plasma and RF power during plasma etching; and
a controller unit that controls each heater zone, wherein the controller infers a target etch temperature at a predetermined location on the substrate from pre-etch critical device parameters measured in the resist layer at a plurality of device die locations on the substrate and post-etch critical device parameters of a previously etched substrate, and adjusts the temperature of each device die location to its target etch temperature using the controllable heater zones,
wherein when the number of heater zones and the number of device die locations are equal, determining a heater power setpoint for the heater zone by multiplying an inverse matrix describing a relationship between a target control parameter for the heater zone and a target etch temperature for the device die location by a vector of the target etch temperatures whose elements are the device die locations;
wherein when the number of heater zones and the number of device die locations are not equal, determining heater power settings for the heater zones based on a matrix describing a relationship between target control parameters for the heater zones and predetermined etch temperatures for the predetermined locations on the substrate;
wherein the heater zones are connected to power supply lines and power return lines, each power supply line and each power return line being connected to a different group of the heater zones; and
wherein the heater zones are connected to a power supply line and a power return line such that no two heater zones are connected to the same pair of power supply line and power return line.
2. The plasma etching system of claim 1, comprising an interface to receive the pre-etch or post-etch critical device parameters via an off-line inspection tool of a host communication network.
3. The plasma etching system of claim 1, wherein the controller determines whether the pre-etch critical device parameter is outside a target value and controls heating of the heater zone so that a post-etch critical device parameter is within the target value.
4. The plasma etching system of claim 1, wherein the heater zones are arranged in a grid.
5. The plasma etching system of claim 1, wherein the heater zone covers 50-90% of an upper substrate supporting surface area of the substrate support assembly.
6. The plasma etching system of claim 1, wherein each heater zone comprises at least one resistive heater.
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